Brassiere insert

ABSTRACT

A brassiere insert for placement within brassiere cups during storage and transportation may be provided. The brassiere insert may be composed of a fluid-impervious thermoplastic film that is sealed along its edges so as to form an inflatable chamber body. The inflatable chamber body may be defined by at least one hemispherical section, configured to fit within an interior portion of the brassiere cup. A valve may be provided at an inlet port along an edge of the chamber body for selectively admitting air and/or other gases into the chamber body for inflation. The brassiere insert may be provided with branding and other merchandising information.

CROSS REFERENCE TO RELATED APPLICATION(S)

The present application claims priority to and the benefit of U.S. Provisional Application No. 62/488,281 filed on Apr. 21, 2017, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE INVENTION

Brassieres are form-fitting undergarments designed to support a woman's bust. Brassieres are typically manufactured as unitary pieces having centrally joined brassiere cups, adjustable shoulder and back straps, and a releasable fastening mechanism. The fastening mechanism can include slide clasps, hooks and eyes, hook-and-loop fasteners, buttons, snaps, releasable adhesives, and the like. The brassiere cups are optionally reinforced with padding material and/or a thin, semi-circular band of rigid underwire extending the base of each cup. Brassieres, and in particular brassiere cups, are generally made from delicate, pliable materials, such as lace, silk, stain, and the like. Accordingly, bra assemblies are not well suited to withstand applied external forces without damaging the fabric and other parts of the brassiere structure.

The ability to maintain the structural integrity of a brassiere during the shipping and transportation process of the supply chain is a well-known problem within the manufacturing industry. Merchandise in transit can be subjected to severe handling conditions, such as rapid movements, vibrations, applied loads, and the like. These conditions can damage the integrity and structure of the brasserie such that the brassiere is deformed by crushing or other forces encountered during shipment. However, brassiere manufacturers cannot bulk up or add packaging to the undergarment, as manufactures must meet packaging reduction requirements in various global geographies, and provide supply chain cost savings. If brassieres are crushed or other otherwise deformed during transit, the aesthetic appeal of the bra could be diminished thereby making it less sellable or not sellable at all.

Accordingly, there is a need in the industry for an improved packaging system that protects brassieres from damage and deformation during the shipping process of the supply chain.

SUMMARY OF THE INVENTION

A brassiere insert for placement within brassiere cups during storage and transportation may be provided. The brassiere insert may provide a protective packaging implement that maintains the structural integrity of a brassiere by buffering and redistributing applied external forces tending to deform the structure. The brassiere insert may meet or exceed packaging reduction requirements in various global geographies and may provide supply chain cost savings through handling and waste disposal efficiencies.

The brassiere insert may be composed of a fluid-impervious thermoplastic film that is sealed along its edges so as to form an inflatable chamber body. In some exemplary embodiments, the chamber body may be defined by at least one hemispherical section, shaped and configured to fit substantially within an interior portion of a brassiere cup. In another exemplary embodiment, the chamber body may be divided into a number of differentiated inflatable sections, including a first hemispherical section, a second hemispherical section, and a connector section. Each section may be in fluid communication with one another such that the introduction of inflation medium into the chamber body completely inflates the entire brassiere insert. The first and second hemispherical sections may be generally symmetrical and spaced apart via the connector section. Each hemispherical section may be configured to fit within an interior portion of a brassiere cup so as to support the entire undergarment unit.

A valve may be provided at an inlet port along an edge of the chamber body for selectively admitting air and/or other gases into the chamber body for inflation. In some exemplary embodiments, the valve may be a self-sealing valve, for example, that permits an inflation medium to flow into the chamber body and prevents the escape of the inflation medium outward. In other exemplary embodiments, the valve may be a reclosable inflation valve that allows the addition and removal of inflation medium for providing a customizable form fit to the brassiere. Inflation may occur when an inflation medium, such as pressurized air and/or other gases, is introduced into the chamber body through an inflation means coupled to the valve.

In some exemplary embodiments, the brassiere insert may be composed of one or more layers of thermoplastic film, including but not limited to polyethylene, polyurethane, polypropylene, and other suitable elastomeric materials as would be understood by a person having ordinary skill in the art. The thermoplastic film may be printed, heat-sealed, and die cut in one single component to match specific brassiere styles and sizes as described above. A branding or customer facing capability may be printed on an interior or exterior surface of the film. Other indicia can be provided including instructions for recycling or other marketing, promotion or user details.

Other features and advantages of the present invention will become apparent to those skilled in the art from the following detailed description. It is to be understood, however, that the detailed description of the various embodiments and specific examples, while indicating preferred and other embodiments of the present invention, are given by way of illustration and not limitation. Many changes and modifications within the scope of the present invention may be made without departing from the spirit thereof, and the invention includes all such modifications.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of embodiments of the present invention will be apparent from the following detailed description of the exemplary embodiments. The following detailed description should be considered in conjunction with the accompanying figures in which:

FIG. 1 depicts a top perspective view of an exemplary embodiment of a brassiere insert intermediate;

FIG. 2 depicts a top perspective view of a brassiere insert intermediate with a portion removed to illustrate an exemplary embodiment of a brassiere insert configuration;

FIG. 3 depicts a perspective view of an exemplary embodiment of an inflated brassiere insert; and

FIG. 4 depicts a perspective view of another exemplary embodiment of an inflated brassiere insert.

DETAILED DESCRIPTION OF THE INVENTION

Aspects of the invention are disclosed in the following description and related drawings directed to specific embodiments of the invention. Alternate embodiments may be devised without departing from the spirit or the scope of the invention. Additionally, well-known elements of exemplary embodiments of the invention will not be described in detail or will be omitted so as not to obscure the relevant details of the invention. Further, to facilitate an understanding of the description discussion of several terms used herein follows.

As used herein, the word “exemplary” means “serving as an example, instance or illustration.” The embodiments described herein are not limiting, but rather are exemplary only. It should be understood that the described embodiments are not necessarily to be construed as preferred or advantageous over other embodiments. Moreover, the terms “embodiments of the invention”, “embodiments” or “invention” do not require that all embodiments of the invention include the discussed feature, advantage or mode of operation.

FIG. 1 may generally illustrate an exemplary embodiment of a brassiere insert intermediate panel 100 according to the present invention. The brassiere insert intermediate panel 100 may be compose done or more layers of thermoplastic film 102, including but not limited to polyethylene, polyurethane, polypropylene, and any other suitable elastomeric materials as would be understood by a person having ordinary skill in the art. Typically, the brassiere insert is made with 100% virgin polyethylene and nylon resins, which are recyclable materials. Thus, the entire brassiere insert may be recyclable. The brassiere insert may also be made from recycled materials.

Indicia 104 with customer facing capability may be printed on an outer surface of the thermoplastic film 102. The indicia 104 may comprise single or multiple alphanumeric characters, symbols, emblems, images, colors, patterns or designs. In some exemplary embodiments, for example, the indicia 104 may include a logo used to represent a commercial enterprise, organization or individual. In other exemplary embodiments, the indicia 104 may provide instructions for recycling, or other customer details.

The insert intermediate panel 100 may be die cut to an identified shape and size for insertion into a brassiere or similar garment during storage and transportation. The brassiere insert may be formed by overlapping insert intermediate panels 100 and sealing the outer peripheral edges thereof to create an inflatable chamber body therebetween. A small peripheral section along the edges may be left unsealed to provide an inlet conduit for an inflation valve. The panels may be secured together via heat-sealing, gluing, or any other suitable adhesive means as would be understood by a person having ordinary skill in the art.

In some exemplary embodiments, the insert intermediate panels 100 may be sealed together along heat seal “dot” components that force air out and up during the inflation process. These “dot” components are inserted during the die cutting process and act to direct air flow as the brassiere insert is being inflated. One or more of these dots may be used to direct the orientation of the brassiere insert so that the insert forms a desired orientation upon inflation.

Typically, the brassiere inserts are inflated after insertion into the brassiere, however it may be contemplated that the brassiere inserts be inflated before insertion as well. If the brassiere insert is inflated prior to insertion, the waste around the brassiere insert is torn off before or after inflation. The waste may be present due to the tooling required to produce the shapes of the brassiere insert and does not impact inflation.

FIG. 2 may illustrate a brassiere insert intermediate 200 with a portion removed to illustrate an exemplary embodiment of a brassiere insert configuration. The eliminated portion 202 of the intermediate 200 may be substantially circular in shape with a rectangular area 204 protruding therefrom. The rectangular area 204 may illustrate the inlet conduit for a valve assembly and creates an open end for use in inflating the insert.

FIG. 3 may illustrate an exemplary embodiment of an inflated brassiere insert 300. The brassiere insert 400 may be composed of a fluid-impervious thermoplastic film that is sealed along its edges so as to form an inflatable chamber body. The inflatable chamber body may be defined by a hemispherical section 302, shaped and configured to fit substantially within an interior portion of a brassiere cup. A valve 304 may be provided at an inlet port 306 along the circumference 308 of the hemispherical section 302 for selectively admitting air and/or other gases into the chamber body for inflation. In some exemplary embodiments, the valve 304 may be a self-sealing valve, for example, that permits an inflation medium to flow into the chamber body and prevents the escape of the inflation medium outward. In other exemplary embodiments, the valve 304 may be a reclosable inflation valve that allows the addition and removal of inflation medium for providing a customizable form fit to the brassiere. It may also be contemplated that any other type of suitable valve be implemented as would be understood by a person having ordinary skill in the art. Inflation may occur when an inflation medium, such as pressurized air and/or other gases, is introduced into the chamber body through an inflation means coupled to the valve 304. For example, a user may manually inflate the inflation valve 304, or a machine could inflate the valve 304. Once inflated, the brassiere insert may be held in the inflated state for 90 days or longer.

FIG. 4 may illustrate another exemplary embodiment of an inflated brassiere insert 400. The brassiere insert 400 may be composed of a fluid-impervious film that may be thermoplastic that is sealed along its edges so as to form an inflatable chamber body. The inflatable chamber body may be divided into a number of differentiated inflatable sections, including a first hemispherical section 402, a second hemispherical section 404, and a connector section 406. Each section 402, 404, 406 may be in fluid communication with one another such that the introduction of inflation medium into the chamber body completely inflates the entire brassiere insert 400. A valve 408 may be provided at an inlet port 410 along an edge of the chamber body for selectively admitting air and/or other gases into the chamber body for inflation. The first and second hemispherical sections 402, 404 may be generally symmetrical and spaced apart via the connector section 406. Each hemispherical section 402, 404 may be configured to fit within an interior portion of a brassiere cup so as to support the entire undergarment. The connector section 406 may support and maintain the straps of the brassiere.

The brassiere insert of the present invention provides protection for the structure of a brassiere during transportation, shipping, and handling. The brassiere insert prevents the brassiere from becoming wrinkled, tangled, deformed, or collapsing during transit.

The brassiere insert of the present invention can be created in any number of shapes, sizes and styles to accommodate for all variations of commercial brassieres.

In one embodiment presently contemplated, the brassiere insert may be used on the inner portion of a support garment such as a brassiere and the insert can be permanently or removably adhered to the support garment by an adhesive or other means known in the art. For instance, the insert may be removably attached to the support garment by Velcro.

In another embodiment of the present invention, a support garment having at least a layer of fabric with a top and bottom face has at least one partial or full cut along a portion of the support garment such that the insert may be placed between the top and bottom face of the at least one layer of fabric via the cut. The cut may be made by any means knows in the art. The present invention is not limited to one layer of fabric. The fabric can be any material known in the art such a woven or nonwoven material, a jersey-like fabric, a recyclable fabric. For instance a support garment may have a first and second layer of material or fabric such that each of the first and the second layer may have a top and a bottom face wherein the first and second layer of material are connected to one another via means known in the art such as, but not limited to, being sewn to one another. The insert may be placed between the top and bottom face. The present invention contemplates that the insert may be placed between the first and second layer of material at the time of manufacturing of the support garment so that the first and second layer of material are sewn or connected around a plurality of points on the first and second layer of material. In another embodiment, the insert can be removably placed between the first and second layer of material such that a user of the support garment can repeatedly take out and insert the brassiere insert presently set forth. At least one opening may be placed along a portion of the first and second material and the insert may be inserted through the at least opening. This will add in keeping shape of the support garment. The insert can be inflated before or after being inserted through the at least one opening.

In one embodiment of the present invention, a first and second layer of material are provided in order to construct a support garment particularly a brassiere. The first and second layer each have a top and bottom face. The bottom face of the first layer is connected to the top face of the second layer to form a first and second dome section. The first and second dome section each have an outer and interior section. The layers are sewn to one another in one embodiment and the bottom face of the second layer has at least one opening which can be placed along interior of either the first or second dome section such that the insert can be placed through the at least one opening.

The foregoing description and accompanying figures illustrate the principles, preferred embodiments and modes of operation of the invention. However, the invention should not be construed as being limited to the particular embodiments discussed above. Additional variations of the embodiments discussed above will be appreciated by those skilled in the art.

Therefore, the above-described embodiments should be regarded as illustrative rather than restrictive. Accordingly, it should be appreciated that variations to those embodiments can be made by those skilled in the art without departing from the scope of the invention as defined by the following claims. 

What is claimed is:
 1. An insert comprising: at least one panel having at least one layer of film and the insert is cut to a shape and size for insertion into an article having at least one dot component such that the insert is recyclable.
 2. The insert of claim 1, wherein the at least one panel is a plurality of panels that are sealed together by the at least one dot component.
 3. The insert of claim 1, wherein the insert is made with virgin polyethylene and nylon resins.
 4. The insert of claim 1, wherein the at least one layer of film is thermoplastic.
 5. The insert of claim 1, wherein the at least one layer of film comprises indicia.
 6. The insert of claim 5, wherein the indicia comprises single or multiple alphanumeric characters, symbols, emblems, images, colors, patterns or designs.
 7. The insert of claim 1, wherein the article is a brassiere.
 8. An insert for an article comprising: a plurality of intermediate panels such that the plurality of intermediate panels are constructed out of thermoplastic film; and the insert is formed by overlapping the plurality of intermediate panels and the intermediate panels are sealed together by at least one heat seal dot component.
 9. The insert of claim 8, wherein the insert is inflated.
 10. The insert of claim 8, wherein the insert is composed of a fluid-impervious thermoplastic film sealed along its edges to form an inflatable chamber body.
 11. The insert of claim 10, wherein an inflatable chamber body is formed that is defined by a hemispherical section.
 12. The insert of claim 11, wherein the hemispherical section has an inlet port with a valve.
 13. The insert of claim 10, wherein the inflatable chamber body is divided into a plurality of differentiated inflatable sections.
 14. The insert of claim 13, wherein the plurality of differentiated inflatable sections comprises a first hemispherical section, a second hemispherical section and a connector section.
 15. The insert of claim 14, wherein the first and second hemispherical sections are symmetrical and spaced apart via the connector section.
 16. A brassiere insert intermediate comprising: At least one panel comprising at least one film layer and the at least one panel has an eliminated portion substantially circular in shape with a rectangular area; and the rectangular area has an inlet conduit for a valve assembly. 